U.S. patent application number 14/717224 was filed with the patent office on 2015-11-26 for system, method and apparatus for attic rafter extension for storage.
The applicant listed for this patent is CertainTeed Corporation. Invention is credited to Andrew Clyde Brandt, Michael Lembo, David M. Pacana.
Application Number | 20150337528 14/717224 |
Document ID | / |
Family ID | 53502411 |
Filed Date | 2015-11-26 |
United States Patent
Application |
20150337528 |
Kind Code |
A1 |
Brandt; Andrew Clyde ; et
al. |
November 26, 2015 |
SYSTEM, METHOD AND APPARATUS FOR ATTIC RAFTER EXTENSION FOR
STORAGE
Abstract
A support structure may have a base having surfaces including a
top, a bottom, a front, a rear and sides. A first top slot may be
formed in the top and may extend at least partially between the
front and the rear. A second top slot may be formed in the top and
may extend at least partially between the sides. In addition, a
bottom slot may be formed in the bottom. A system for attic storage
can include an attic having attic joists. A plurality of support
structures, each comprising a base, may be mounted to the attic
joists. At least two conventional lumber studs may be included and
may extend between adjacent ones of the bases. In addition, a
plurality of lumber panels may be mounted to at least one of the
bases and the lumber studs.
Inventors: |
Brandt; Andrew Clyde;
(Pottstown, PA) ; Pacana; David M.; (Spring City,
PA) ; Lembo; Michael; (Souderton, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CertainTeed Corporation |
Valley Forge |
PA |
US |
|
|
Family ID: |
53502411 |
Appl. No.: |
14/717224 |
Filed: |
May 20, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62001903 |
May 22, 2014 |
|
|
|
Current U.S.
Class: |
52/483.1 ;
206/231; 206/526; 248/214 |
Current CPC
Class: |
E04B 5/023 20130101;
E04B 1/40 20130101; E04F 2015/02066 20130101; E04B 5/14 20130101;
E04F 15/02044 20130101; E04B 5/12 20130101; B65D 85/70 20130101;
E04B 5/43 20130101; E04F 2015/02055 20130101; E04B 2103/04
20130101 |
International
Class: |
E04B 1/41 20060101
E04B001/41; E04B 5/12 20060101 E04B005/12; B65D 85/00 20060101
B65D085/00 |
Claims
1. A support structure, comprising: a base having surfaces
including a top, a bottom, a front, a rear and sides; a first top
slot formed in the top and extending at least partially between the
front and the rear; a second top slot formed in the top and
extending at least partially between the sides; and a bottom slot
formed in the bottom.
2. The support structure of claim 1, wherein the first top slot
comprises a top front slot that extends from the front to adjacent
a center of the top, and a top rear slot that extends from the rear
to adjacent the center of the top.
3. The support structure of claim 2, wherein the top front slot is
separated from the top rear slot by the second top slot.
4. The support structure of claim 2, wherein the top front slot
extends along the front from the top to adjacent a center of the
front, and the top rear slot extends along the rear from the top to
adjacent a center of the rear.
5. The support structure of claim 1, wherein the first and second
top slots intersect and extend completely across the top, and the
top comprises a third top slot for a total of only three slots in
the top.
6. The support structure of claim 1, wherein the top comprises a
third top slot and a fourth top slot, and none of the top slots
intersect each other.
7. The support structure of claim 1, wherein the slots are
orthogonal to each other.
8. The support structure of claim 1, wherein the second top slot
extends completely across the top from side to side, and the bottom
slot is the only slot in the bottom, and the bottom slot extends
completely across the bottom from front to back, or from side to
side.
9. The support structure of claim 1, wherein the base comprises a
density of at least about 0.5 lb/ft.sup.3, and not greater than
about 25 lb/ft.sup.3.
10. The support structure of claim 1, wherein the base has an
insulation rating of at least about R0.5/inch, and not greater than
about R9/inch.
11. The support structure of claim 1, wherein the base comprises: a
nail pull strength of at least about 10 lbs, and not greater than
about 350 lbs; and a screw hold strength of at least about 25 lbs,
and not greater than about 1000 lbs.
12. The support structure of claim 1, wherein the base has a
compressive strength of at least about 15 lbs/ft.sup.2, and not
greater than about 600 lbs/ft.sup.2.
13. The support structure of claim 1, wherein the base comprises at
least one of an inorganic material, an organic material, an organic
material other than wood, fungal material, mycelium foam, an open
cell structure, a closed cell structure, a polymeric foam, a rigid
polyurethane, polystyrene, polypropylene, a cellular plastic and a
rigid plastic.
14. A system for attic storage, comprising: an attic having attic
joists; a plurality of support structures, each comprising a base,
mounted to the attic joists; at least two conventional lumber studs
extending between adjacent ones of the bases; and a plurality of
lumber panels mounted to at least one of the bases and the lumber
studs.
15. The system of claim 14, wherein at least some of the bases have
three or four lumber studs mounted thereto and extending to other
bases.
16. The system of claim 14, wherein tops of the bases and tops of
the lumber studs are substantially flush with each other.
17. The system of claim 14, wherein at least some of the bases are
not mounted to adjacent ones of the joists, such that at least some
of the joists beneath the plurality of lumber panels do not have
bases mounted to them.
18. The system of claim 14, wherein at least some of the lumber
studs comprise 2.times.4 inch studs, and the lumber panels comprise
at least one of a sheet of wood, particle board, plywood, oriented
strand board (OSB).
19. A kit, comprising: at least four support structures, each
comprising a base, and each of the bases comprises: surfaces
including a top, a bottom, a front, a rear and sides; a first top
slot formed in the top and extending at least partially between the
front and the rear; a second top slot formed in the top and
extending at least partially between the sides; and a bottom slot
formed in the bottom; and the kit further comprises: a container
for containing the at least four support structures.
20. The kit of claim 19, wherein the kit comprises an attic storage
kit, and the container comprises a bag or a box; and further
comprising: at least one of fasteners, lumber, hardware, an
installation tool and a template for installation.
Description
[0001] This application claims priority to and the benefit of U.S.
Prov. App. No. 62/001,903, filed May 22, 2014, which is
incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Disclosure
[0003] The present invention relates in general to attic storage
and, in particular, to a system, method and apparatus for attic
rafter extensions for storage purposes.
[0004] 2. Description of the Related Art
[0005] The use of home attics for storage space is a common
practice. However, the conventional attic architecture of an attic
floor covered by protruding rafters and loose fill or batt
insulation is not very conducive to forming a storage space.
Constructing a storage space in an attic can cause the insulation
to be displaced or compressed, which reduces its insulation
properties and effectiveness. Some solutions for attic storage
involve the use of platforms. Such platforms tend to rest on top of
the attic rafters that protrude upward from the attic floor. These
platforms can limit the insulation effectiveness to below code
requirements. Thus, improvements in attic storage continue to be of
interest.
SUMMARY
[0006] Embodiments of a system, method and apparatus for attic
storage are disclosed. For example, a support structure may have a
base having surfaces including a top, a bottom, a front, a rear and
sides. A first top slot may be formed in the top and may extend at
least partially between the front and the rear. A second top slot
may be formed in the top and may extend at least partially between
the sides. In addition, a bottom slot may be formed in the
bottom.
[0007] In other embodiments, a system for attic storage can include
an attic having attic joists. A plurality of support structures,
each comprising a base, may be mounted to the attic joists. At
least two conventional lumber studs may be include and may extend
between adjacent ones of the bases. In addition, a plurality of
lumber panels may be mounted to at least one of the bases and the
lumber studs.
[0008] In still other embodiments, a kit can have at least four
support structures, each comprising a base. Each of the bases can
include surfaces including a top, a bottom, a front, a rear and
sides. A first top slot may be formed in the top and may extend at
least partially between the front and the rear. A second top slot
may be formed in the top and may extend at least partially between
the sides. A bottom slot may be formed in the bottom. The kit also
may include a container for containing the at least four bases.
[0009] The foregoing and other objects and advantages of these
embodiments will be apparent to those of ordinary skill in the art
in view of the following detailed description, taken in conjunction
with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] So that the manner in which the features and advantages of
the embodiments are attained and can be understood in more detail,
a more particular description may be had by reference to the
embodiments thereof that are illustrated in the appended drawings.
However, the drawings illustrate only some embodiments and
therefore are not to be considered limiting in scope as there may
be other equally effective embodiments.
[0011] FIG. 1 is a front isometric view of an embodiment of a
support structure.
[0012] FIG. 2 is a front view of an embodiment of a support
structure.
[0013] FIG. 3 is a top view of an embodiment of a support
structure.
[0014] FIG. 4 is a front isometric view of an embodiment of an
attic storage system partially installed on rafters.
[0015] FIG. 5 is a front isometric view of an embodiment of an
attic storage system at a stage of installation subsequent to FIG.
4.
[0016] FIG. 6 is a front isometric view of an embodiment of an
attic storage system at a stage of installation subsequent to FIG.
5.
[0017] FIG. 7 is a front isometric view of an embodiment of an
attic storage system at a stage of installation subsequent to FIG.
6.
[0018] FIGS. 8A and 8B are top views of alternate embodiments of
partially installed attic storage systems.
[0019] FIG. 9 is a side isometric view of an embodiment of an
installed attic storage system.
[0020] The use of the same reference symbols in different drawings
indicates similar or identical items.
DETAILED DESCRIPTION
[0021] Embodiments of a system, method and apparatus for an attic
storage solution are disclosed. For example, as shown in FIG. 1, a
support structure 21 may comprise a base 23. Although the base 23
is depicted as a block in a substantially rectilinear
configuration, many other shapes and sizes (e.g., curvilinear, such
as spherical are feasible depending on the application. The base 23
can be substantially cubic in shape. In addition, the base 23 can
be solid or hollow.
[0022] Embodiments of the base 23 can have surfaces, including a
top 25, a bottom 27, a front 29, a rear 31 and sides 33, 35. Some
versions of the base 23 may include one or more apertures, such as
slots. Each slot may be configured to receive conventional lumber
studs, as described elsewhere herein.
[0023] For example, and as shown in FIGS. 1-3, a first top slot 41
(e.g., a top front slot 41) may be formed in the top 25. The first
top slot 41 can extend at least partially between the front 29 and
the rear 31. In the embodiment shown (FIG. 3), the top front slot
41 can extend from the front 29 to adjacent a center of the top 25.
In addition, the top front slot 41 can extend along the front 29
(FIG. 2) from the top 25 to adjacent a center of the front 29.
[0024] In some embodiments, the first top slot 41 further comprises
a top rear slot 43 as well. The second top slot 43 can extend at
least partially between the sides 33, 35. In the embodiment shown
(FIG. 3), the top rear slot 43 can extend from the rear 31 to
adjacent the center of the top 25. In addition, the top rear slot
43 (FIG. 3) can extend along the rear 31 from the top 25 to
adjacent a center of the rear 31.
[0025] Embodiments of the base 23 may include a second top slot 45
formed in the top 25. As shown in FIG. 3, the second top slot 45
can extend completely across the top 25 from side 33 to side
35.
[0026] In some versions, the top front slot 41 can be separated
from the top rear slot 43 by the second top slot 45. Alternatively,
the first and second top slots 41, 45 can intersect (not shown) and
extend completely across the top 25. When base 23 is configured as
illustrated herein, the top 25 may comprise the third top slot
(e.g., top rear slot 43) for a total of only three slots 41, 43, 45
in the top 25. In still another embodiment, the top 25 comprises a
fourth top slot which is not shown, but essentially the second top
slot 45 configured as two slots, like slots 41, 43, such that none
of the four top slots intersect each other.
[0027] Embodiments of the base 23 may include a bottom slot 47
formed in the bottom 27. For example, the bottom slot 47 can extend
partially or completely across the bottom 23 from front 29 to back
31, or from side 33 to side 35. In some versions, the bottom slot
47 is the only slot in the bottom 23. The bottom slot 47 may be
oriented perpendicular to the second top slot 45.
[0028] In some versions, all of the slots 41, 43, 45, 47 can be
orthogonal to each other. In other versions, at least two of the
slots 41, 43, 45, 47 can intersect each other at an angle that is
not orthogonal. In another embodiment, the slots 41, 43, 45, 47 can
be orthogonal to each other, but not orthogonal to the surfaces of
the base 23. In alternate embodiments, the slots 41, 43, 45, 47 are
not orthogonal to each other, and not orthogonal to the surfaces of
the base 23. In still another embodiment, none of the slots 41, 43,
45, 47 intersect each other.
[0029] Embodiments of the support structure 21 may include a base
23 formed from one or more materials. For example, an entirety of
the base 23 may be formed from a single material, or a composite of
materials. The base 23 also may include one or more reinforcement
materials and/or structures. In other examples, a stronger material
can be used to reinforce the base in areas where other elements
engage with it. In a particular embodiment, the slots 41, 43, 45,
47 could be reinforced with one or more materials such as metal,
plastic and wood to improve the strength of the system at the
connection points.
[0030] In some embodiments, the base 23 may comprise at least one
of an inorganic material, an organic material, an organic material
other than wood, fungal material and mycelium foam. In other
examples, the base 23 may comprise at least one of an open cell
structure, a closed cell structure, a polymeric foam, a rigid
polyurethane, polystyrene, polypropylene, a cellular plastic and a
rigid plastic. In still other embodiments, the base 23 may comprise
one or more of the materials disclosed in U.S. Pat. No. 8,001,719,
and U.S. Publications 2013/0295368 and 2014/0056653, each of which
is incorporated herein by reference in its entirety.
[0031] Other versions of the support structure 21 may include the
base 23 comprising one or more specific properties. For example,
the base 23 can have at least one of the following properties.
[0032] Embodiments of the base 23 can have a desirable density. For
example, the density of the base can be at least about 0.5
lb/ft.sup.3. In other versions, the base can have a density of at
least about 1 lb/ft.sup.3, at least about 2 lb/ft.sup.3, at least
about 5 lb/ft.sup.3, or even at least about 10 lb/ft.sup.3. In
still other embodiments, the base can have a density of not greater
than about 25 lb/ft.sup.3, such as not greater than about 20
lb/ft.sup.3, not greater than about 15 lb/ft.sup.3, not greater
than about 12 lb/ft.sup.3, or even not greater than about 10
lb/ft.sup.3. Other embodiments of the base material can have a
density in a range between any of these values.
[0033] Some embodiments of the base can have a desirable insulation
rating. For example, the insulation rating of the base can be at
least about R0.5/inch. Other versions of the base can have an
insulation rating of at least about R1/inch, such as at least about
R2/inch, at least about R3/inch, at least about R4/inch, or even at
least about R5/inch. In other examples, the base material can have
an insulation rating of not greater than about R9/inch, such as not
greater than about R8/inch, not greater than about R7/inch, not
greater than about R6/inch, not greater than about R5/inch, or even
not greater than about R4/inch. Other embodiments of the base
material can have an insulation rating in a range between any of
these values.
[0034] Embodiments of the base material can have other desirable
properties such as, for example, fastener retention performance.
The fasteners may comprise screws or nails. Fastener retention
performance may be defined by an industry standard, such as ASTM
D1037. In some versions, the screw hold strength or nail pull
strength of embodiments disclosed herein can be similar to that for
conventional #2 yellow pine lumber.
[0035] In some embodiments, the nail pull strength of the base
material for a 16d nail can be at least about 5 lbs. In other
versions, the nail pull strength can be at least about 10 lbs, such
as at least about 25 lbs, at least about 50 lbs, at least about 100
lbs, or even at least about 150 lbs. In other versions, the nail
pull strength can be not greater than about 350 lbs, such as not
greater than about 300 lbs, not greater than about 250 lbs, not
greater than about 200 lbs, not greater than about 150 lbs, or even
not greater than about 100 lbs. Other embodiments of the base
material can have a nail pull strength in a range between any of
these values.
[0036] In other embodiments, the base material can have a screw
hold strength (for a 1/2'' lag screw) of at least about 25 lbs. For
example, the screw hold strength can be at least about 35 lbs, at
least about 50 lbs, at least about 100 lbs, at least about 200 lbs,
at least about 300 lbs, or even at least about 400 lbs. In still
other versions, the screw hold strength can be not greater than
about 1000 lbs, such as not greater than about 900 lbs, not greater
than about 800 lbs, not greater than about 700 lbs, not greater
than about 600 lbs, or even not greater than about 500 lbs. Other
embodiments of the base material can have a screw hold strength in
a range between any of these values.
[0037] Embodiments of the base material also can have a desirable
compression or crush resistance. For compressive strength, it can
be desirable that the base element have a compressive resistance of
at least about 15 lbs/ft.sup.2. Such a value can represent a
reduction in thickness of the base material of about 10% for a
general load support. In other versions, the compressive resistance
can be at least about 25 lbs/ft.sup.2, such as at least about 40
lbs/ft.sup.2, at least about 50 lbs/ft.sup.2, at least about 60
lbs/ft.sup.2, or even at least about 70 lbs/ft.sup.2. In other
examples, the compressive strength can be not greater than about
600 lbs/ft.sup.2, such as not greater than about 500 lbs/ft.sup.2,
not greater than about 400 lbs/ft.sup.2, not greater than about 300
lbs/ft.sup.2, not greater than about 200 lbs/ft.sup.2, not greater
than about 150 lbs/ft.sup.2, not greater than about 125
lbs/ft.sup.2, or even not greater than about 100 lbs/ft.sup.2.
Other embodiments of the base material can have a compressive
resistance in a range between any of these values.
[0038] The support structure 21 may further comprise a ruler 51
(FIGS. 2 and 9). The ruler 51 may be formed on or affixed to at
least one surface (e.g., the front 29) of base 23.
[0039] Referring now to FIGS. 4-8, embodiments of a system and
method of forming a support surface in an attic for attic storage
are disclosed. The system may comprise an attic having attic joists
61 (FIG. 4), such as those shown extending upward from an attic
floor. In conventional home construction, the attic joists 61
comprise continuous beams and have no slots. A plurality of support
structures 21 or bases 23 may be mounted to the attic joists 61.
Each base 23 may be configured in any of the embodiments described
herein.
[0040] In one embodiment, the bottom slots 47 of the bases 23
receive the attic joists 61. In some versions, the bases 23 do not
directly contact each other, and are spaced apart from other on the
attic joists 61. The bases 23 may be positioned on the attic joists
61 and attached with or without fasteners, such as nails or screws.
If fasteners are used, the bases 23 may be attached to the attic
joists 61 in any suitable manner. For example, FIG. 1 depicts base
23 with pre-drilled holes or designated locations 37 for fastener
attachments to attic joists 61. In addition, locations similar to
locations 37 and/or fasteners could be used in conjunction with any
or all of the slots 41, 43, 45, 47.
[0041] In some embodiments, the bases 23 make contact and rest only
on the attic joists 61, such that the bases 23 do not make contact
with the attic floor. Such versions may include a space or
clearance directly beneath the bottoms 27 of the bases 23, and
above the attic floor.
[0042] As shown in FIG. 5, a plurality of conventional lumber studs
71 may be installed and extend between the bases 23. For example,
at least some of the lumber studs 71 may comprise 2.times.4 inch
studs. In one embodiment, a lumber stud 71 may extend from the top
rear slot 43 of a first base 23 (e.g., the left-most bases 23 in
FIG. 5), to the top front slot 41 of a second base 23 (e.g., the
right-most bases 23 in FIG. 5). Such lumber studs 71 may be cut at
a desired length, such as a desired spacing (e.g., four feet)
between adjacent ones of the bases 23, such as those on the same
attic joist 61.
[0043] In some versions, additional lumber studs 71 (FIG. 6) may be
used between adjacent ones of the bases 23, such as those that are
not on the same attic joist 61. For example, these additional
lumber studs 71 may extend through the second top slots 45 of
adjacent ones of the bases 23. Embodiments of the system and method
may include the tops 25 of the bases being flush with the tops of
the lumber studs 71, as shown. Thus, in some embodiments, the bases
23 are connected to two or more other bases 23 (e.g., two, three or
four other bases 23; see FIG. 8B) by the lumber studs 71.
[0044] In the embodiments of FIGS. 5-7, the lumber studs 71 may be
vertically oriented, whereas in the embodiments of FIGS. 8A and 8B
the lumber studs 71 may be horizontally oriented. Such orientations
affect the configuration and shape of the bases and their slots.
The lumber studs 71 may be positioned on the bases 23 and attached
with or without fasteners.
[0045] In addition, one or more conventional lumber panels 81 may
be mounted to the lumber studs 71. In some examples, at least some
of the lumber panels 81 may comprise at least one of a sheet of
wood, particle board, plywood, oriented strand board (OSB). The
lumber panels 81 may be configured with a width that exceeds a
depth thereof. For example, typical lumber panels can be in a
variety of width to thickness ratios, such as 8:1, 12:1, 16:1,
24:1, or even as high as 96:1. In some embodiments, the lumber
panels are of sufficient length that they extend beyond at least
two of the parallel lumber studs 71.
[0046] The lumber panels 81 may be positioned on the bases 23 and
lumber studs 71, and attached with or without fasteners. If
fasteners are used, the bases 23, lumber studs 71 and lumber panels
81 may be attached in any suitable manner. The lumber panels 81
form the top platform for the attic storage support surface.
[0047] In some embodiments, at least some of the bases 23 are not
mounted to adjacent ones of the attic joists 61, such that at least
some of the attic joists 61 beneath the lumber panels 81 do not
have bases 23 mounted to them.
[0048] The system and method may include embodiments wherein no
insulation is located on the floor of the attic, at least between
the joists 61 prior to mounting the bases 23 to the joists 61.
Embodiments may further comprise adding insulation after the bases
23 are installed (for example, after lumber studs 71 are installed,
but before lumber panels 81 are installed and completion of the
entire support surface), such that at least some of the insulation
is added between the attic floor and the bottoms 27 of the bases
23. In some versions (FIG. 9), at least some of the insulation 91
extends to an elevation above the bottoms 27 of the bases 23 and
below a lower surface of the support surface formed by the lumber
panels 81.
[0049] In other embodiments, insulation is located on the attic
floor, at least between the attic joists 61, prior to mounting the
bases 23 to the joists 61. In some versions, at least some of the
insulation is compressed by the bases 23 when the bases 23 are
mounted to the attic joists 61. In other versions, the insulation
can be temporarily cleared away from the locations of the bases 23
prior to their installation on attic joints 61. The cleared
insulation can be returned to positions on the attic floor (FIG. 9)
adjacent to and in contact with the bases 23 after the bases 23 are
installed on attic joists 61.
[0050] In still other embodiments, a kit, such as an attic storage
kit, may comprise a plurality of the bases 23 in a container (e.g.,
a bag or box). The kit may include one or more of the following
items including, for example, fasteners, lumber, additional
hardware, installation tools, and templates for installation.
[0051] Embodiments also may comprise one or more of the following
items.
[0052] Item 1. A support structure, comprising: [0053] a base
having surfaces including a top, a bottom, a front, a rear and
sides; [0054] a first top slot formed in the top and extending at
least partially between the front and the rear; [0055] a second top
slot formed in the top and extending at least partially between the
sides; and
[0056] a bottom slot formed in the bottom.
[0057] Item 2. The support structure of item 1, wherein the first
top slot comprises a top front slot that extends from the front to
adjacent a center of the top, and a top rear slot that extends from
the rear to adjacent the center of the top.
[0058] Item 3. The support structure of item 2, wherein the top
front slot is separated from the top rear slot by the second top
slot.
[0059] Item 4. The support structure of item 2, wherein the top
front slot extends along the front from the top to adjacent a
center of the front.
[0060] Item 5. The support structure of item 2, wherein the top
rear slot extends along the rear from the top to adjacent a center
of the rear.
[0061] Item 6. The support structure of item 1, wherein the first
and second top slots intersect and extend completely across the
top.
[0062] Item 7. The support structure of item 1, wherein the top
comprises a third top slot for a total of only three slots in the
top.
[0063] Item 8. The support structure of item 1, wherein the top
comprises a third top slot and a fourth top slot, and none of the
top slots intersect each other.
[0064] Item 9. The support structure of item 1, wherein all of the
slots are orthogonal to each other.
[0065] Item 10. The support structure of item 1, wherein at least
two of the slots intersect each other at an angle that is not
orthogonal.
[0066] Item 11. The support structure of item 1, wherein the slots
are orthogonal to each other, but not orthogonal to the surfaces of
the base.
[0067] Item 12. The support structure of item 1, wherein the slots
are not orthogonal to each other, and not orthogonal to the
surfaces of the base.
[0068] Item 13. The support structure of item 1, wherein none of
the slots intersect each other.
[0069] Item 14. The support structure of item 1, wherein the second
top slot extends completely across the top from side to side.
[0070] Item 15. The support structure of item 1, wherein the bottom
slot is the only slot in the bottom, and the bottom slot extends
completely across the bottom from front to back, or from side to
side.
[0071] Item 16. The support structure of item 1, wherein each slot
is configured to receive conventional lumber studs.
[0072] Item 17. The support structure of item 1, wherein the base
is solid or hollow.
[0073] Item 18. The support structure of item 1, wherein the base
is a block that is substantially rectangular in shape,
substantially cubic in shape, substantially curvilinear in shape,
or substantially spherical in shape.
[0074] Item 19. The support structure of item 1, wherein an
entirety of the base is formed from a single material or from a
composite of materials.
[0075] Item 20. The support structure of item 1, wherein the base
comprises at least one of an inorganic material, an organic
material, an organic material other than wood, fungal material,
mycelium foam, an open cell structure, a closed cell structure, a
polymeric foam, a rigid polyurethane, polystyrene, polypropylene, a
cellular plastic and a rigid plastic.
[0076] Item 21. The support structure of item 1, wherein the base
comprises a density of at least about 0.5 lb/ft3, at least about 1
lb/ft3, at least about 2 lb/ft3, at least about 5 lb/ft3, at least
about 10 lb/ft3, not greater than about 25 lb/ft3, not greater than
about 20 lb/ft3, not greater than about 15 lb/ft3, not greater than
about 12 lb/ft3, not greater than about 10 lb/ft3.
[0077] Item 22. The support structure of item 1, wherein the base
has an insulation rating of at least about R0.5/inch, at least
about R1/inch, at least about R2/inch, at least about R3/inch, at
least about R4/inch, at least about R5/inch, not greater than about
R9/inch, not greater than about R8/inch, not greater than about
R7/inch, not greater than about R6/inch, not greater than about
R5/inch, not greater than about R4/inch.
[0078] Item 23. The support structure of item 1, wherein the base
has a nail pull strength of at least about 10 lbs, at least about
25 lbs, at least about 50 lbs, at least about 100 lbs, at least
about 150 lbs, not greater than about 350 lbs, not greater than
about 300 lbs, not greater than about 250 lbs, not greater than
about 200 lbs, not greater than about 150 lbs, not greater than
about 100 lbs.
[0079] Item 24. The support structure of item 1, wherein the base
has a screw hold strength of at least about 25 lbs, at least about
50 lbs, at least about 100 lbs, at least about 200 lbs, at least
about 300 lbs, at least about 400 lbs, not greater than about 1000
lbs, not greater than about 900 lbs, not greater than about 800
lbs, not greater than about 700 lbs, not greater than about 600
lbs, not greater than about 500 lbs.
[0080] Item 25. The support structure of item 1, wherein the base
has a compressive strength of at least about 15 lbs/ft2, at least
about 25 lbs/ft2, at least about 40 lbs/ft2, at least about 50
lbs/ft2, at least about 60 lbs/ft2, at least about 70 lbs/ft2, not
greater than about 600 lbs/ft2, not greater than about 500 lbs/ft2,
not greater than about 400 lbs/ft2, not greater than about 300
lbs/ft2, not greater than about 200 lbs/ft2, not greater than about
175 lbs/ft2, not greater than about 150 lbs/ft2, not greater than
about 125 lbs/ft2, not greater than about 100 lbs/ft2.
[0081] Item 26. The support structure of item 1, further comprising
a ruler on at least one of surfaces.
[0082] Item 27. A system for attic storage, comprising:
[0083] an attic having attic joists;
[0084] a plurality of support structures, each comprising a base,
mounted to the attic joists;
[0085] at least two conventional lumber studs extending between
adjacent ones of the bases; and
[0086] a plurality of lumber panels mounted to at least one of the
bases and the lumber studs.
[0087] Item 28. The system of item 27, wherein at least some of the
bases have three or four lumber studs mounted thereto and extending
to other bases.
[0088] Item 29. The system of item 27, wherein tops of the bases
and tops of the lumber studs are substantially flush with each
other.
[0089] Item 30. The system of item 27, wherein at least some of the
bases are not mounted to adjacent ones of the joists, such that at
least some of the joists beneath the plurality of lumber panels do
not have bases mounted to them.
[0090] Item 31. The system of item 27, wherein at least some of the
lumber studs comprise 2.times.4 inch studs, and the lumber panels
comprise at least one of a sheet of wood, particle board, plywood,
oriented strand board (OSB).
[0091] Item 32. The system of item 27, wherein at least some of the
support structures are configured according to one or more of items
1-26.
[0092] Item 33. A method of forming a support surface in an attic,
the attic having a floor, and attic joists extending upward from
the floor, the method comprising:
[0093] mounting a plurality of support structures, each comprising
a base, to the attic joists;
[0094] mounting two or more studs to at least some of the bases;
and
[0095] mounting at least one panel to at least one of the bases and
the studs to form a support structure.
[0096] Item 34. The method of item 33, wherein insulation is
located on the floor of the attic at least between the joists prior
to mounting the bases to the joists, such that at least some of the
insulation is compressed by the bases when the bases are mounted to
the joists.
[0097] Item 35. The method of item 33, wherein no insulation is
located on the floor of the attic at least between the joists prior
to mounting the bases to the joists, and further comprising adding
insulation after completion of the support surface, such that at
least some of the insulation is added between the floor of the
attic and the bottoms of the bases, and at least some of the
insulation extends to an elevation above the bottoms of the bases
and below a lower surface of the support surface.
[0098] Item 36. The method of item 33, wherein at least some of the
support structures are configured according to one or more of items
1-26.
[0099] Item 37. A kit, comprising: [0100] at least four support
structures, each comprising a base, and each of the bases
comprises:
[0101] surfaces including a top, a bottom, a front, a rear and
sides;
[0102] a first top slot formed in the top and extending at least
partially between the front and the rear;
[0103] a second top slot formed in the top and extending at least
partially between the sides; and
[0104] a bottom slot formed in the bottom; and the kit further
comprises:
[0105] a container for containing the at least four support
structures.
[0106] Item 38. The kit of item 37, wherein the kit comprises an
attic storage kit, and the container comprises a bag or a box.
[0107] Item 39. The kit of item 37, further comprising at least one
of fasteners, lumber, hardware, an installation tool and a template
for installation.
[0108] Item 40. The kit of item 37, wherein at least some of the
support structures are configured according to one or more of items
1-26.
[0109] Item 41. A system for attic storage according to any one of
the preceding items, the system comprising:
[0110] an attic having attic joists;
[0111] a plurality the support structures, each mounted to the
attic joists;
[0112] at least two lumber studs extending between adjacent ones of
the support structures; and
[0113] a plurality of lumber panels mounted to at least one of the
support structures and the lumber studs.
[0114] Item 42. An attic storage kit according to any one of the
preceding items, the attic storage kit comprising:
[0115] at least four of the support structures; and
[0116] a container for containing the at least four support
structures.
[0117] The embodiments disclosed herein can increase storage space
in attics, where studs and rafters may be covered by loose fill
insulation. In some versions, pre-molded attic rafter extensions
allow a platform to be installed at a higher height than the top of
the attic rafters, such as about 8 inches to about 12 inches. The
rafter extensions can provide a storage space and allow access over
insulation up to about R-60. This design enables a user to access
attic storage without stepping in or crushing installed loose fill
insulation. The rafter extensions may be installed, and then
additional common lumber can be placed on top of the extensions to
make the platform area. In some embodiments such as residential
home attics, the embodiments may be utilized either during the
initial installation of insulation, or as a part of a retrofit
after installation has been installed. The extensions may be formed
from a material that is structurally strong enough to support
loads, but still offer insulating value itself, while not forming a
thermal bridge through the loose fill insulation.
[0118] This written description uses examples to disclose the
embodiments, including the best mode, and also to enable those of
ordinary skill in the art to make and use the invention. The
patentable scope is defined by the claims, and may include other
examples that occur to those skilled in the art. Such other
examples are intended to be within the scope of the claims if they
have structural elements that do not differ from the literal
language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages
of the claims.
[0119] Note that not all of the activities described above in the
general description or the examples are required, that a portion of
a specific activity may not be required, and that one or more
further activities may be performed in addition to those described.
Still further, the order in which activities are listed are not
necessarily the order in which they are performed.
[0120] In the foregoing specification, the concepts have been
described with reference to specific embodiments. However, one of
ordinary skill in the art appreciates that various modifications
and changes can be made without departing from the scope of the
invention as set forth in the claims below. Accordingly, the
specification and figures are to be regarded in an illustrative
rather than a restrictive sense, and all such modifications are
intended to be included within the scope of invention.
[0121] As used herein, the terms "comprises," "comprising,"
"includes," "including," "has," "having" or any other variation
thereof, are intended to cover a non-exclusive inclusion. For
example, a process, method, article, or apparatus that comprises a
list of features is not necessarily limited only to those features
but may include other features not expressly listed or inherent to
such process, method, article, or apparatus. Further, unless
expressly stated to the contrary, "or" refers to an inclusive-or
and not to an exclusive-or. For example, a condition A or B is
satisfied by any one of the following: A is true (or present) and B
is false (or not present), A is false (or not present) and B is
true (or present), and both A and B are true (or present).
[0122] Also, the use of "a" or "an" are employed to describe
elements and components described herein. This is done merely for
convenience and to give a general sense of the scope of the
invention. This description should be read to include one or at
least one and the singular also includes the plural unless it is
obvious that it is meant otherwise.
[0123] Benefits, other advantages, and solutions to problems have
been described above with regard to specific embodiments. However,
the benefits, advantages, solutions to problems, and any feature(s)
that may cause any benefit, advantage, or solution to occur or
become more pronounced are not to be construed as a critical,
required, or essential feature of any or all the claims.
[0124] After reading the specification, skilled artisans will
appreciate that certain features are, for clarity, described herein
in the context of separate embodiments, may also be provided in
combination in a single embodiment. Conversely, various features
that are, for brevity, described in the context of a single
embodiment, may also be provided separately or in any
subcombination. Further, references to values stated in ranges
include each and every value within that range.
* * * * *